IMTS Pavilion: Gear Generation
with great efficiency. The VL 2 machines workpieces with a maximum diameter of 4" (102 mm) and a length up to 6" (152 mm). Increasing in size, the VL 4, VL 6 and VL 8 offer
The company’s vice president of Sales–Cutting Tools, Tom Bell, delved into some of the details of these areas. “Longer tool life, more parts per regrind,” he said, “are a constant topic from large OEMs, particularly in automotive. The advancement in substrate material—steels and carbide types—and coatings have impacted tool performances the greatest,” he said. “This ultimately gives end-users better performing and longer lasting tooling.”
A modular gear manufacturing system can be created by using (from left) two EMAG VL 2s, a VLC 200 H and a VLC 100 D.
a number of different turning and milling operations within the framework of a single closed-loop production process. Specially designed to handle large components, the largest, the VL 8, is well suited for commercial vehicle production, with the ability to handle workpieces up to 16" (406 mm) in diameter and 12" (305-mm) long.
“From the machine tool point of view, these new gear grinding abrasives require an extremely rigid design.”
The VT-Series for machining large quantities of shaft com- ponents employs the same modular concept. With four axes, a self-loading turret and integrated automation, the VT 2-4 machines shafts with a max diameter of 2.5" (63.5 mm) and 16" long. Spindle speeds of up to 6000 rpm achieve extremely short cycle times as the shaft is clamped vertically between work spindle and tailstock and machined from two sides. The vertical alignment of the workpiece ensures process integrity, where the unhindered chip flow prevents the build-up of chip nests in the machining area.
Looking at the Big Picture David Goodfellow, president of Star SU LLC (Hoffman Estates, IL), said his customers also take a big-picture view of gear making: “Larger customers want a fully integrated sup- plier who can provide machine tool and cutting tool design, tryout, automation, reconditioning of tools and technical sup- port of the full process.”
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Bell also noted that tool simulation to better predict cutting tool behavior has been of great benefit in gear making. In addition, Bell said, the end users desire for quietness and “the goal to maximize power transfer from gearing have led to more sophisticated tolerances” even as “faster cycle times are required by gearmakers.” Bell said Star SU’s focus at IMTS will be on advanced material for high performance hobbing, the G250 Vertical Gear Grinder, as well as its national channel partnership with Sandvik Coromant for gear milling tools.
In addition, Star SU, will be displaying its new larger port- folio based on its newly extended partnership with FFG Werke GmbH, a German machine tool manufacturer. The Star SU portfolio now also covers VDF Boehringer and Hessapp turn- ing machines as well as Hüller Hille machining centers and Witzig & Frank multiway, multispindle machines. ME
—James D. Sawyer
Single-Table Gear Grinding Machine With a one-table design and a new-design grinding head, the LGG 180 and LGG 280 noticeably reduce grinding times for twist-free profile and generating grinding. The machines are designed to deliver consistent large-scale high-production quality in automotive applications, including conical gearing. The advantage to the one-table solution is higher qual- ity throughout the entire production. There is one clamp- ing fixture, one geometry. Every ma- chined part is manu- factured under the same conditions for the highest repro- ducibility. The one- table approach pro- vides the statistical
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